1. Manufacturing Technology

2. Introduction and Agenda
Materials Properties
- helps to determine how to make things with it
- helps to determine the processing conditions
- helps and constrains process optimization
Processes
- forming, cutting, non-traditional, joining,
surface treatments, electronics components, …
Process Planning
CNC programming
Process Evaluation and Quality control
Process Economics and Optimization
Product design and Fabrication

3. Motivation (1) A bottle of water (~HK$6)
Four components (bottle, cap, label, water)
- How are each of these manufactured?
- What does the equipment cost?

4. Boeing 747 plane: ~6 million parts
Motivation (2)
Stapler (~HK$ 45)
Approx. 15 components
- How do we select the best material for each component?
- How are each of these manufactured?
Car: ~ 15,000 parts;
Boeing 747 plane: ~6 million parts
Intel core 2 duo processor: 65 nm feature size, 291 million transistors

5. Materials
Ferrous metals: carbon-, alloy-, stainless-, tool-and-die steels
Non-ferrous metals: aluminum, magnesium, copper, nickel,
titanium, superalloys, refractory metals,
beryllium, zirconium, low-melting alloys,
gold, silver, platinum, …
Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,…)
thermosets (epoxies, Polymides, Phenolics, …)
elastomers (rubbers, silicones, polyurethanes, …)
Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride
Composites: reinforced plastics, metal-, ceramic matrix composites
Nanomaterials, shape-memory alloys, superconductors, …

6. Properties of materials
Mechanical properties of materials
Strength, Toughness, Hardness, Ductility,
Elasticity, Fatigue and Creep
Physical properties
Density, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties
Chemical properties
Oxidation, Corrosion, Flammability, Toxicity, …

9. Failure in Tension, Young’s modulus and Tensile strength
Engineering stress = s = P/Ao
Engineering strain = e = (L – Lo)/Lo = d/Lo

10. Failure in Tension, Young’s modulus and Tensile strength..
Original
Final
Necking
Fracture

11. Failure in Tension, Young’s modulus and Tensile strength…
In the linear elastic range: Hooke’s law: s = E e or, E = s/e
E: Young’s modulus

12. Elastic recovery after plastic deformation

13. True Stress, True Strain, and Toughness
Final
Necking
Fracture
Engg stress and strain are “gross” measures:
s = F/A => s is the average stress ≠ local stress
e = d/Lo => e is average strain
Toughness = energy used to fracture
= area under true stress-strain curve
engg strain d/Lo
true strain ln(L/Lo)
true stress P/A
engg stress P/Ao
fracture

14. Measures how much the material can be stretched before fracture
Ductility
Measures how much the material can be stretched before fracture
Ductility = 100 x (Lf – Lo)/Lo
High ductility: platinum, steel, copper
Good ductility: aluminum
Low ductility (brittle): chalk, glass, graphite
- Walkman headphone wires: Al or Cu?

15. Hardness
resistance to plastic deformation by indentation

16. Shear stress and Strain: the torsion testL g C C’ q T D d
Angle of twist: q = TL/GJ
Shear stress: t = Tr/J
Maximum shear stress = tmax = TR/J
Shear strain = g = rq/L
T = torque,
J = polar moment of inertia
J =  r2 dA
Cylindrical shell: J = p( D4-d4)/32
t = G g
G: Modulus of rigidity

17. Shear strength and Tensile strength
[approximate relation between shear and tensile strengths]
Ultimate Tensile Strength = Su Ultimate Shear Strength = Ssu
Tensile Yield Strength = Syp Shear yield point = Ssyp
Material
Tensile-Relation
Yield-Relation
Wrought Steel & alloy steel
Ssu ≈ 0.75 x Su
Ssyp = Approx 0,58 x Syp
Ductile Iron
Ssu ≈ 0.90 x Su
Ssyp = Approx 0,75 x Syp
Cast Iron
Ssu ≈ 1.3 x Su -
Copper & alloys
Ssu ≈ [ ] x Su
Aluminum & alloys
Ssu ≈ 0.65 xSu
Ssyp = Approx 0,55 x Syp
References: Machine design Theory and Practice .A.D.Deutschman, W.A Michels & C.E. Wilson.. MacMillan Publishing 1975.

18. Fatigue
Fracture/failure of a material subjected cyclic stresses
S-N curve for compressive loading

19. Failure under impact
Application: Drop forging
Testing for Impact Strength

20. Strain Hardening
- Metals microstructure: crystal-grains
- Under plastic strain, grains slipping along boundaries
- Locking up of grains => increase in strength
- We can see this in the true-stress-strain curve also
Applications:
- Cold rolling, forging: part is stronger than casting

21. Residual stresses
Internal stresses remaining in material after it is processed
Causes:
- Forging, drawing, …: removal of external forces
- Casting: varying rate of solidification, thermal contraction
Problem: warping when machined, creep
Releasing residual stresses: annealing

22. Physical Properties Property Application (e.g.)
Density, r = mass/volume
Drop forging, hammering
Specific heat
Coolant in machining
Thermal conductivity
Cutting titanium
Coeff of linear thermal expansion, a = DL/(L DT)
Compensation in Casting, …
Melting point
Brazing, Casting, …
Electrical conductivity
EDM, ECM, Plating
Magnetic properties
Magnetic chucking

23. Summary
Materials have different physical, chemical, electrical properties
Knowledge of materials’ properties is required to
Select appropriate material for design requirement
Select appropriate manufacturing process
Optimize processing conditions for economic manufacturing …
Reference: Chapter 2, Chapter 3, Mfg Engg & Tech, Kalpakjian & Schmid